Additive Manufacturing Fluid Pump Cases Tilted Orientation
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Solution Overview
Problem
Traditional fuel pump manufacturing methods and designs make it difficult to additively manufacture fluid pumps that are both economical and effective, as they often require non-build plate support structures within internal apertures, which can be costly and complex.
Innovation Solution
The method involves additively manufacturing fluid pump cases in a tilted orientation without internal non-build plate support structures, except for coincidental locations intended for post-processing milling, allowing for the elimination of support structures and enabling efficient production of fluid pumps with unique internal features like teardrop-shaped channels and volute surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional molding and machining methods are used to manufacture fuel pumps, then manufacturing precision and reliability are maintained, but manufacturing cost and complexity increase
Solution Approach 1:
The patent combines multiple manufacturing operations (molding, machining, support structure installation and removal) into a single additive manufacturing process. The fluid pump case is manufactured in one additive build operation with all features including internal apertures, eliminating the need for separate molding and machining steps, thereby reducing manufacturing cost and process complexity
Solution Approach 2:
The patent inverts the traditional manufacturing approach by using additive manufacturing instead of subtractive manufacturing. Rather than molding and then machining away material to create internal features, the patent builds the fluid pump case layer by layer with all internal features directly formed, eliminating the need for complex support structures and post-processing operations
2Device complexity
If additively manufactured fluid pump cases are produced with tilted orientation, then support structure requirements are eliminated, but manufacturing precision challenges arise
Solution Approach 1:
The patent employs asymmetric orientation of the fluid pump case during additive manufacturing, tilting the build orientation at specific angles (e.g., 45 degrees from horizontal). This asymmetric positioning allows internal apertures to be formed without requiring support structures that would interfere with fluid flow, while the tilted orientation naturally prevents powder accumulation and ensures dimensional accuracy through proper build plate positioning
3Object-generated harmful factors
If internal apertures are created without support structures, then fluid flow paths are improved, but structural stability during manufacturing may be compromised
Solution Approach 1:
The patent resolves the conflict between creating open internal apertures and maintaining structural stability by changing the manufacturing dimension from subtractive to additive. The additive process builds the fluid pump case layer by layer, with each layer providing inherent support for subsequent layers. Internal apertures are formed as void spaces within the layered structure, eliminating the need for support structures that would obstruct fluid flow while maintaining structural integrity through the build process itself
Data Source
AI summary
In accordance with at least one aspect of this disclosure, embodiments of fluid pumps, pump cases, valve bodies, and volutes are disclosed herein. Embodiments of methods for manufacturing fluid pumps, pump cases, valve bodies, and volutes are also disclosed herein. Embodiments can include additive manufacturing, for example. Certain embodiments can include additively manufacturing a pump case in a tilted orientation, utilizing only coincidental support structure having a unique shape, and with teardrop shaped volute and/or valve body.